Sheet Tobacco Flavoring via Fiber-Solution Separation
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Solution Overview
Problem
The existing methods for manufacturing American Blend-type cigarettes require large-scale equipment and high costs for special processing treatments, which involve adding casing flavor to burley leaves and drying, limiting productivity and increasing expenses, especially for tobacco factories without the necessary equipment.
Innovation Solution
A method that separates raw materials into fiber and solution, adds casing flavor to the solution, mixes and dries it to create sheet tobacco, adjusts moisture content, and applies a secondary casing treatment to both sheet and burley leaf tobaccos, reducing the need for the special processing treatment and minimizing burley leaf tobacco usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If special processing treatment (adding casing flavor to burley leaves and drying) is applied, then distinctive sweet odor and taste are created, but large-scale equipment and installation space are required
Solution Approach 1:
The invention changes the processing parameters by applying casing flavor treatment to sheet tobacco instead of burley leaves, and by adjusting moisture content parameters during the drying process to achieve the desired sweet odor and taste without requiring large-scale special processing equipment
Solution Approach 2:
The invention creates a copy of the special processing treatment effect by applying casing flavor to sheet tobacco and burley leaf tobacco separately, then blending them to reproduce the distinctive sweet odor and taste of traditionally processed American Blend cigarettes without needing the original multiple-chamber dryer system
2Manufacturing precision
If special processing treatment is applied, then distinctive sweet odor and taste are created, but high running costs are incurred
Solution Approach 1:
The invention optimizes the moisture content parameters and casing flavor application method to reduce energy consumption during the drying process, thereby lowering running costs while maintaining the quality of the sweet odor and taste
3Ease of manufacture
If special processing treatment equipment is not available, then treatment can be entrusted to other factories, but productivity deteriorates
Solution Approach 1:
The invention segments the special processing treatment into separate steps that can be performed independently on sheet tobacco and burley leaf tobacco, allowing each step to be carried out in standard equipment without requiring centralized special processing facilities, thereby maintaining productivity
Solution Approach 2:
The invention makes the casing flavor treatment process universally applicable to different tobacco types (sheet tobacco and burley leaf tobacco) using standard equipment, eliminating the need for specialized multiple-chamber dryers and enabling any tobacco factory to perform the treatment independently
4Manufacturing precision
If burley leaf tobacco is used in conventional amounts, then adequate flavor is achieved, but special processing treatment is required
Solution Approach 1:
The invention changes the processing approach by adjusting moisture content parameters and applying casing flavor to sheet tobacco during manufacturing, then blending with burley leaf tobacco, which simplifies the overall processing complexity while maintaining adequate flavor quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of cigarettes with a smoky sweet flavor equivalent to conventionally treated burley leaf tobacco, reducing equipment and space requirements while maintaining aroma and flavor quality, thus enabling cost-effective manufacturing without the need for the special processing treatment.
Implementation Method 1
adding a casing flavor to the solution
Implementation Method 2
drying the mixture to produce sheet tobacco
Data Source
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AI summary
A method of manufacturing sheet tobacco for producing a cigarette that has equivalent aroma and flavor even if the amount of burley leaves is reduced, and does not require a special processing treatment due to the absence of necessity of an installation space and costs for the treatment, a method of manufacturing a cigarette containing the same, and a cigarette. The invention separates raw material for sheet tobacco into fiber and solution, adds a casing flavor to the solution, mixes the solution added with the casing flavor and the fiber to produce a mixture, and dries the mixture. The casing flavor is previously added at the time of the molding of sheet tobacco in the sheet-tobacco manufacturing process, which makes it possible to produce sheet tobacco having the aroma and flavor equivalent of when burley leaf tobacco is used, even without applying the special processing treatment.